CN116867844A - Impermeable films comprising polymer blends and methods of making the same - Google Patents
Impermeable films comprising polymer blends and methods of making the same Download PDFInfo
- Publication number
- CN116867844A CN116867844A CN202280015309.0A CN202280015309A CN116867844A CN 116867844 A CN116867844 A CN 116867844A CN 202280015309 A CN202280015309 A CN 202280015309A CN 116867844 A CN116867844 A CN 116867844A
- Authority
- CN
- China
- Prior art keywords
- film
- anhydride
- weight
- olefin interpolymer
- carboxylic acid
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 28
- 229920002959 polymer blend Polymers 0.000 title abstract description 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims abstract description 49
- 239000005977 Ethylene Substances 0.000 claims abstract description 49
- 150000008064 anhydrides Chemical class 0.000 claims abstract description 46
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims abstract description 37
- 239000004711 α-olefin Substances 0.000 claims abstract description 37
- 239000011256 inorganic filler Substances 0.000 claims abstract description 34
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 34
- 229920000092 linear low density polyethylene Polymers 0.000 claims abstract description 28
- 239000004707 linear low-density polyethylene Substances 0.000 claims abstract description 27
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 32
- 238000002844 melting Methods 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 17
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 claims description 16
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 16
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 16
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 16
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 16
- 239000000155 melt Substances 0.000 claims description 9
- 229910021536 Zeolite Inorganic materials 0.000 claims description 8
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 8
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims description 8
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 8
- 239000000292 calcium oxide Substances 0.000 claims description 8
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 8
- QXJJQWWVWRCVQT-UHFFFAOYSA-K calcium;sodium;phosphate Chemical compound [Na+].[Ca+2].[O-]P([O-])([O-])=O QXJJQWWVWRCVQT-UHFFFAOYSA-K 0.000 claims description 8
- 239000004927 clay Substances 0.000 claims description 8
- 229910052570 clay Inorganic materials 0.000 claims description 8
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 8
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 8
- 239000001095 magnesium carbonate Substances 0.000 claims description 8
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 8
- 239000000395 magnesium oxide Substances 0.000 claims description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 8
- 229910052943 magnesium sulfate Inorganic materials 0.000 claims description 8
- 235000019341 magnesium sulphate Nutrition 0.000 claims description 8
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 8
- 239000010445 mica Substances 0.000 claims description 8
- 229910052618 mica group Inorganic materials 0.000 claims description 8
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 8
- 239000000454 talc Substances 0.000 claims description 8
- 229910052623 talc Inorganic materials 0.000 claims description 8
- 239000004408 titanium dioxide Substances 0.000 claims description 8
- 239000010457 zeolite Substances 0.000 claims description 8
- 239000002253 acid Substances 0.000 claims description 7
- 230000005540 biological transmission Effects 0.000 claims description 7
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical group O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 230000000052 comparative effect Effects 0.000 description 29
- 239000000203 mixture Substances 0.000 description 17
- 229920000642 polymer Polymers 0.000 description 15
- 239000000126 substance Substances 0.000 description 15
- 238000009472 formulation Methods 0.000 description 11
- 238000001125 extrusion Methods 0.000 description 8
- 239000010410 layer Substances 0.000 description 7
- 239000000654 additive Substances 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000000178 monomer Substances 0.000 description 6
- 239000000945 filler Substances 0.000 description 5
- 239000004594 Masterbatch (MB) Substances 0.000 description 4
- 229920003313 Bynel® Polymers 0.000 description 3
- 206010021639 Incontinence Diseases 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- 229920001684 low density polyethylene Polymers 0.000 description 3
- 239000004702 low-density polyethylene Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- OCKGFTQIICXDQW-ZEQRLZLVSA-N 5-[(1r)-1-hydroxy-2-[4-[(2r)-2-hydroxy-2-(4-methyl-1-oxo-3h-2-benzofuran-5-yl)ethyl]piperazin-1-yl]ethyl]-4-methyl-3h-2-benzofuran-1-one Chemical compound C1=C2C(=O)OCC2=C(C)C([C@@H](O)CN2CCN(CC2)C[C@H](O)C2=CC=C3C(=O)OCC3=C2C)=C1 OCKGFTQIICXDQW-ZEQRLZLVSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- -1 ++>168 Chemical compound 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 238000003855 Adhesive Lamination Methods 0.000 description 1
- 229920003314 Elvaloy® Polymers 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 241000282376 Panthera tigris Species 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- BAPJBEWLBFYGME-UHFFFAOYSA-N acrylic acid methyl ester Natural products COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000002671 adjuvant Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 239000004599 antimicrobial Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- XXHCQZDUJDEPSX-KNCHESJLSA-L calcium;(1s,2r)-cyclohexane-1,2-dicarboxylate Chemical compound [Ca+2].[O-]C(=O)[C@H]1CCCC[C@H]1C([O-])=O XXHCQZDUJDEPSX-KNCHESJLSA-L 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000008395 clarifying agent Substances 0.000 description 1
- 238000010622 cold drawing Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000007765 extrusion coating Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229940127554 medical product Drugs 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 238000012858 packaging process Methods 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000012549 training Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/06—Polyethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/26—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment
- C08L23/30—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment by oxidation
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/08—Copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2423/04—Homopolymers or copolymers of ethene
- C08J2423/08—Copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/26—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers modified by chemical after-treatment
- C08J2423/30—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers modified by chemical after-treatment by oxidation
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2451/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2451/06—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
- C08K2003/265—Calcium, strontium or barium carbonate
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2207/00—Properties characterising the ingredient of the composition
- C08L2207/06—Properties of polyethylene
- C08L2207/066—LDPE (radical process)
Abstract
The present application provides impermeable films comprising specific polymer blends and methods for making such films. The film comprises an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, a linear low density polyethylene, and an inorganic filler. Methods of making the film include extruding an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, a linear low density polyethylene, and an inorganic filler to form a film and stretching the film. Films according to embodiments disclosed herein may exhibit low WVTR values and improved modulus while also incorporating a large amount of low gauge inorganic filler.
Description
Technical Field
Embodiments of the present disclosure relate generally to films, and more particularly to impermeable films comprising specific polymer blends.
Background
Impermeable films are used in a wide variety of applications including infant diapers, adult incontinence products, surgical gowns, and other hygiene and medical applications. For example, diaper backsheet films may be classified as breathable or non-breathable films according to the microporous morphology or water vapor transmission rate ("WVTR") of the film. Breathable films are typically made by incorporating a significant amount (greater than 30% by weight) of an inorganic filler (e.g., caCO) 3 ) To be incorporated into polymers to create pores, deliver breathability and reduce cost. Although the impermeable film may contain fillers such as CaCO 3 To reduce costs, but they do not contain large amounts (greater than 30% by weight) of fillers, because fillers such as CaCO 3 Holes can be created, air permeability delivered, and mechanical properties compromised. Alternatively, the impermeable film is typically formed from a blend of High Density Polyethylene (HDPE), linear Low Density Polyethylene (LLDPE), and Low Density Polyethylene (LDPE), wherein, broadly speaking, HDPE provides stiffness, LLDPE provides toughness, and LDPE provides processability.
Thus, there remains a need for cost-effective, gas impermeable film formulations that contain inorganic fillers and that exhibit improved or maintained mechanical properties such as modulus and tensile properties.
Disclosure of Invention
Embodiments of the present disclosure provide a high level (40 wt.% to 70 wt.%) of inorganic filler and a low WVTR (less than 1,100 g/m) 2 * Day) film meets the aforementioned needs. The films of the present application comprise an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer and a linear low density polyethylene. Without being bound by any theory, the combination of the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer with the linear low density polyethylene and the inorganic filler prevents cavitation and thus reduces or removes breathability while maintaining or improving mechanical properties. Films according to embodiments disclosed herein may exhibit low WVTR values and improved modulus while also incorporating a large amount of low gauge inorganic filler.
Disclosed herein is a membrane. The film comprises (a) 1 to 15% by weight of an anhydride and/or carboxylic acidA functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃; (b) 20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And (c) 40 to 70 wt% of an inorganic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; and wherein weight% is based on the total weight of the film; and wherein the film has a weight of less than 1,100g/m 2 * A Water Vapor Transmission Rate (WVTR) over days and a draw ratio of at least 2:1.
Also disclosed herein is a method for making the film. The method comprises providing from 1 wt% to 15 wt% of an anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃;20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And 40 to 70 wt% of an inorganic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; wherein weight% is based on the total weight of the film; extruding the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, linear low density polyethylene, and inorganic filler to form the film; and stretching the film to a stretch ratio of at least 2:1.
These and other embodiments are described in more detail in the detailed description.
Detailed Description
Aspects of the disclosed films are described in more detail below. The films may have a wide variety of applications including, for example, infant diapers, adult incontinence products, surgical gowns, and other hygiene and medical applications. This disclosure may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth in this disclosure. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art.
As used herein, the term "polymer" means a polymeric compound prepared by polymerizing the same or different types of monomers. The generic term polymer thus embraces the term homopolymer (employed to refer to polymers prepared from only one type of monomer) and the term copolymer or interpolymer. Trace impurities (e.g., catalyst residues) may be incorporated into and/or within the polymer. The polymer may be a single polymer, a blend of polymers, or a mixture of polymers, including a mixture of polymers formed in situ during polymerization.
As used herein, the term "polyethylene" refers to a polymer comprising a majority (> 50 mol%) of units derived from ethylene monomers.
As used herein, the term "interpolymer" refers to a polymer prepared by the polymerization of at least two different types of monomers.
As used herein, the term "ethylene/a-olefin interpolymer" refers to an interpolymer that comprises, in polymerized form, a majority of ethylene monomer (based on the weight of the interpolymer), and at least one a-olefin monomer.
As used herein, the term "anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer" refers to an ethylene/α -olefin interpolymer that comprises at least one anhydride group and/or at least one acid group (e.g., -COOH formed by hydrolysis of an anhydride) attached by a covalent bond. Examples of anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymers are maleic anhydride functionalized ethylene/alpha-olefin interpolymers.
The terms "comprises," comprising, "" includes, "" including, "" having, "" has, "" with their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the components, steps or procedures are specifically disclosed. For the avoidance of any doubt, unless stated to the contrary, all compositions claimed through use of the term "comprising" may include any additional additive, adjuvant or compound whether polymeric or otherwise. In contrast, the term "consisting essentially of …" excludes any other component, step or procedure from any subsequently enumerated scope, except for those components, steps or procedures that are not essential to operability. The term "consisting of … …" excludes any ingredient, step or procedure not specifically recited or listed.
The films disclosed herein comprise an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, a linear low density polyethylene, and an inorganic filler.
In embodiments, the film comprises 1 to 15 weight percent ("wt%") of the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer, wherein the wt% is based on the total weight of the film. All individual values and subranges from 1 to 15 weight percent are disclosed and included herein. For example, the film may comprise from 1 wt% to 15 wt%, from 5 wt% to 15 wt%, or from 8 wt% to 12 wt% of the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer, wherein the wt% is based on the total weight of the film.
In embodiments, the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer has a melting point of less than 100 ℃, wherein the melting point can be measured according to ISO 3146. All individual values and subranges from less than 100 ℃ are disclosed and included herein. For example, the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer may have a melting point of less than 100 ℃, less than 95 ℃, less than 90 ℃, less than 85 ℃, less than 80 ℃, less than 75 ℃, less than 70 ℃, or less than 65 ℃; or may have a melting point in the range of 55 ℃ to 95 ℃, 55 ℃ to 85 ℃, 55 ℃ to 75 ℃, 55 ℃ to 65 ℃, 60 ℃ to 90 ℃, 60 ℃ to 80 ℃, or 60 ℃ to 70 ℃, wherein the melting point may be measured according to ISO 3146.
In embodiments, the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer has a molecular weight of less than 0.910 grams per cubic centimeter (g/cm 3 Or g/cc). All individual values and subranges from less than 0.910g/cc are disclosed and included herein.For example, the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer may have a density less than 0.910g/cc, less than 0.900g/cc, less than 0.890g/cc, less than 0.880g/cc, or less than 0.870 g/cc; or may have a density in the range of 0.860g/cc to 0.910g/cc, 0.860g/cc to 0.900g/cc, 0.860g/cc to 0.890g/cc, 0.860g/cc to 0.880g/cc, or 0.865g/cc to 0.875 g/cc.
In embodiments, the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer has an anhydride or acid content from 0.1 weight percent to 2.0 weight percent, wherein the weight percent of the anhydride or acid content is based on the total weight of the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer. All individual values and subranges from 0.1 to 2.0 weight percent are disclosed herein and included herein. For example, the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer may have an anhydride or acid content of from 0.1 wt% to 2.0 wt%, from 0.3 wt% to 2.0 wt%, from 0.5 wt% to 2.0 wt%, from 0.7 wt% to 2.0 wt%, or from 1.0 wt% to 2.0 wt%, wherein the wt% of the anhydride or acid content is based on the total weight of the anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer.
In embodiments, anhydride and/or carboxylic acid functional groups are grafted onto the ethylene/a-olefin interpolymer.
In embodiments, the anhydride and/or carboxylic acid functionalized ethylene/a-olefin interpolymer is a maleic anhydride functionalized ethylene/a-olefin interpolymer. For example, in embodiments, the film comprises 1 to 15 wt% of a maleic anhydride functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃, wherein the wt% is based on the total weight of the film.
Examples of anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymers suitable for use in embodiments of the present application include those sold under the trade name BYNEL TM Is an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer including, for example, BYNEL TM 46E1060, commercially available from the dow chemical company (The Dow Chemical Company, midland, MI) of Midland, michigan.
The films disclosed herein comprise linear low density polyethylene. In embodiments, the film comprises 20 wt% to 59 wt% linear low density polyethylene, wherein wt% is based on the total weight of the film. All individual values and subranges from 20 to 59 weight percent are disclosed and included herein. For example, the film may comprise 20 wt% to 59 wt%, 20 wt% to 50 wt%, 20 wt% to 45 wt%, 30 wt% to 59 wt%, 30 wt% to 50 wt%, 30 wt% to 45 wt%, 35 wt% to 59 wt%, 35 wt% to 50 wt%, or 35 wt% to 45 wt% of the linear low density polyethylene, wherein wt% is based on the total weight of the film.
In embodiments, the linear low density polyethylene has 0.900g/cm 3 To 0.940g/cm 3 Is a density of (3). Disclosed and included herein is 0.900g/cm 3 To 0.940g/cm 3 Is included, and all individual values and subranges thereof. For example, the linear low density polyethylene may have a density of 0.900g/cm 3 To 0.940g/cm 3 、0.905g/cm 3 To 0.935g/cm 3 、0.910g/cm 3 To 0.930g/cm 3 Or 0.915g/cm 3 To 0.925g/cm 3 Wherein the density is measurable according to ASTM D792.
In embodiments, the linear low density polyethylene has a melt index (I) of from 0.1g/10min to 10.0g/10min 2 ). All individual values and subranges from 0.1g/10min to 10.0g/10min are disclosed herein and included herein. For example, the linear low density polyethylene may have a melt index (I) of 0.1g/10min to 10.0g/10min, 0.5g/10min to 10.0g/10min, 1.0g/10min to 10.0g/10min, 0.1g/10min to 5.0g/10min, 0.5g/10min to 5.0g/10min, or 1.0g/10min to 5.0g/10min 2 ) Wherein the melt index (I 2 ) Can be measured according to ASTM D1238.
Examples of linear low density polyethylenes suitable for use in embodiments of the present application include those sold under the trade name DOWLEX TM Including, for example, DOWLEX commercially available from Dow chemical company (The Dow Chemical Company, midland, mich.) of Midland, mich TM 2111GC polyethylene resin.
The films disclosed herein also comprise an inorganic filler. The inorganic filler is selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof. In embodiments, the film comprises 40 to 70 weight percent of an organic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof. All individual values and subranges from 40 to 70 weight percent are disclosed and included herein. For example, the composition may comprise from 40 wt% to 70 wt%, from 40 wt% to 60 wt%, from 40 wt% to 55 wt%, from 45 wt% to 70 wt%, from 45 wt% to 60 wt%, or from 45 wt% to 55 wt% of the inorganic filler, wherein wt% is based on the total weight of the film.
In embodiments, the inorganic filler has a median particle size (D50) of less than 5 micrometers (also referred to as micrometers (μm)). All individual values and subranges from less than 5 microns are disclosed and included herein. For example, the inorganic filler may have a median particle size (D50) of less than 4 microns, less than 3 microns, less than 2 microns, or less than 1 micron, or may be in the range of 0.1 microns to 4 microns, 0.1 microns to 3 microns, 0.1 microns to 2 microns, or 0.1 microns to 1 micron.
In embodiments, the inorganic filler of the film is calcium carbonate.
The films disclosed herein can incorporate additives such as antioxidants (e.g., hindered phenols such as1010 or->1076 supplied by BASF), phosphite (e.g., ++>168, also from barSchiff supply), processing aids, ultraviolet light stabilizers, heat stabilizers, pigments, colorants, antistatic additives, flame retardants, slip agents, antiblocking additives, biocides, antimicrobial agents, and clarifying/nucleating agents (e.g., HYPERFORM) TM HPN-20E、MILLAD TM 3988、MILLAD TM NX 8000, available from Milliken chemical Co., ltd (Milliken Chemical). Additives may be included in the films at levels commonly used in the art to achieve their desired purpose. In some examples, the content of the one or more additives ranges from 0 wt% to 10 wt% based on the total weight of the film, from 0 wt% to 5 wt% based on the total weight of the film, from 0.001 wt% to 3 wt% based on the total weight of the film, from 0.05 wt% to 3 wt% based on the total weight of the film, or from 0.05 wt% to 2 wt% based on the total weight of the film.
The films disclosed herein are impermeable to air. As used herein, the term "gas impermeable" means having less than 1,100g/m 2 * Films of Water Vapor Transmission Rate (WVTR) in days. The films of the present application can allow higher amounts of inorganic filler (40 wt% to 70 wt% inorganic filler) while maintaining lower WVTR values (less than 1,100g/m 2 * Day). This result is unexpected because higher levels of filler generally result in greater cavitation and higher WVTR values in the film. Without being bound by any theory, the combination of the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer with the linear low density polyethylene and the inorganic filler prevents cavitation and thus reduces WVTR while maintaining or improving mechanical properties. It is believed that anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymers may interact with the inorganic filler and linear low density polyethylene to prevent cavitation and reduce pore formation and WVTR.
The films disclosed herein have less than 1,100g/m 2 * Water vapor transmission rate over the day (WVTR). Less than 1,100g/m is disclosed and incorporated herein 2 * All individual values and subranges of the day. For example, the film may have a weight of less than 1,100g/m 2 * Day, less than 1,000g/m 2 * Day, less than 900g/m 2 * Day, less than 800g/m 2 * A heaven,Less than 700g/m 2 * Day, less than 600g/m 2 * Day, or less than 500g/m 2 * WVTR of day; or the film may have a molecular weight of 400 to 1,100g/m 2 * Day, 400 to 1,000g/m 2 * Day, 400 to 800g/m 2 * Day, 400 to 600g/m 2 * Day, 500 to 1,100g/m 2 * Day, or 500 to 800g/m 2 * WVTR over the day range, wherein WVTR may be measured according to ASTM E398.
The basis weight of the film is not particularly limited, but in some embodiments may be 5gsm to 50gsm. The basis weight of the film may depend on a variety of factors including the desired properties of the film, the end use application of the film, the equipment available to make the film, the cost allowed by the application, and other factors. All individual values and subranges from 5gsm to 50gsm are included herein and disclosed herein. For example, in some embodiments, the film has a basis weight of 5gsm to 50gsm, 5gsm to 40gsm, 5gsm to 30gsm, 5gsm to 20gsm, 10gsm to 50gsm, 10gsm to 40gsm, 10gsm to 30gsm, or 10gsm to 20 gsm.
The films disclosed herein have a draw ratio of at least 2:1. Although stretching a film may increase the WVTR, stretching may increase or improve the mechanical properties of the film, such as modulus and stretching properties, and may allow for a reduction in film gauge. The films of the present application according to embodiments disclosed herein allow for higher levels of inorganic filler while maintaining WVTR at low levels (less than 1,100g/m 2 * Day) and at the same time maintain or improve mechanical properties such as modulus or tensile properties. In embodiments, the film has a draw ratio of at least 2:1, at least 3:1, at least 4:1, or at least 5:1, or has a draw ratio in the range of 2:1 to 6:1, or alternatively 3:1 to 6:1.
Except that it has a weight of less than 1,100g/m 2 * In addition to a WVTR of days and a stretch ratio of at least 2:1, a film according to embodiments disclosed herein may have a force at 5% strain in the machine direction of greater than 2.000N/15mm film width (or alternatively greater than 2.500N/15mm film width, or greater than 3.000N/15mm film width, or greater than 3.500N/15mm film width, or greater than 4.000N/15mm film width), wherein the force at 5% strain in the machine direction may be measured according to the test method described below.
Films according to embodiments disclosed herein may be defined in terms of their force at 5% strain in the Machine Direction (MD), draw ratio, weight% of inorganic filler, and WVTR. For example, the following equation may be used to characterize the film:
in embodiments, the film has X NBB It is greater than or equal to 0.0060, or greater than or equal to 0.0080, or greater than or equal to 0.0100, wherein X NBB As defined in the above equation.
It is also contemplated that films according to embodiments disclosed herein may comprise additional layers that are co-extruded or as laminates. These layers may be selected to provide additional functionality, such as layers that provide additional strength, adhesion to another substrate (such as a nonwoven), and/or aesthetic properties (such as feel or appearance).
Some embodiments of the application relate to laminates comprising one or more films of the application. For example, the films of the present application may be used in film/nonwoven laminates. Typical nonwoven fabrics for such laminates may be spun webs, air-laid webs, carded webs, or composites thereof. Typical nonwoven composites for laminates with films of the present application include three strands of spunbond material (e.g., S/S), spunbond/meltblown/spunbond composites (e.g., S/M/S), and the like. Common methods for joining the film to the nonwoven include, for example, bonded hot melt adhesive lamination, ultrasonic bonding, and thermal bonding by calender or nip rolls. In embodiments, a laminate comprising a film of the present application is in adhering contact with a nonwoven or a second film.
The present application also relates to articles comprising at least one film of the present application disclosed herein. Articles comprising the films of the present application may be used as liquid impermeable layers in disposable hygiene and medical products. Examples of articles that include such films include diapers, training pants, feminine hygiene products, adult incontinence products, medical drapes, medical gowns, surgical gowns, and the like. Films may be incorporated into such articles using techniques known to those skilled in the art based on the teachings herein.
The films described herein can be prepared by a variety of processes. Exemplary processes may include forming the film into a blown film or a cast film, and the film may be manufactured by a blown, cast, or extrusion coating process. The film may be stretched by machine direction stretching, transverse direction stretching, ring rolling stretching, cold drawing, or a combination thereof.
Also disclosed herein are methods of making the films of the application. In an embodiment, a method for making a film includes providing from 1 wt% to 15 wt% of an anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃;20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And 40 to 70 wt% of an inorganic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; wherein weight% is based on the total weight of the film; extruding the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, linear low density polyethylene, and inorganic filler to form the film; and stretching the film to a stretch ratio of at least 2:1.
In an embodiment, a method of making a film comprises the steps of: anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymers, linear low density polyethylene, and inorganic fillers are compounded prior to extruding the material into a film. For example, in embodiments, a method for making a film includes providing from 1 wt% to 15 wt% of an anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃;20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And 40 to 70 wt% of an inorganic filler, the inorganic fillerThe material is selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; wherein weight% is based on the total weight of the film; compounding an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, a linear low density polyethylene, and an inorganic filler to form a masterbatch formulation; extruding the masterbatch formulation to form a film; and stretching the film to a stretch ratio of at least 2:1.
Test method
Density of
Density is measured according to ASTM D792 and is measured in grams/cm 3 (g/cc or g/cm) 3 ) And (3) representing.
2 Melt index (I)
Melt index (I) 2 ) Measured at 190℃under 2.16kg according to ASTM D-1238. Values are reported in g/10min, which correspond to grams eluted per 10 min.
Melting point
Melting points were measured according to ISO 3146.
Water Vapor Transmission Rate (WVTR)
The Water Vapor Transmission Rate (WVTR) is measured according to ASTM E398.
Force or absolute stretching at 5% strain in MD
The force at 5% strain in the machine direction (also called absolute stretching) was measured according to ISO 527-3. Stress at 5% elongation is recorded. The width of the sample was 15mm, its length was 100mm, and the recorded value was N/15mm film width.
Examples
The following examples illustrate features of the present disclosure, but are not intended to limit the scope of the present disclosure.
The materials used
The following materials are included in the exemplary films discussed below.
DOWLEX TM 2107GC, an ethylene-octene copolymer having a density of 0.917g/cm 3 And melt index (I) 2 ) Is 2.3g/10min, commercially available from the Dow chemical company (The Dow Chemical Company, midland, mich.) of Midland, mich.
DOWLEX TM 2111GC, which is a linear low density polyethylene, has a density of 0.920g/cm 3 And melt index (I) 2 ) Is 3.7g/10min, commercially available from the Dow chemical company (The Dow Chemical Company, midland, mich.) of Midland, mich.
BYNEL TM 46E1060, which is a maleic anhydride functionalized ethylene/alpha-olefin interpolymer, has a melting point of 62.8℃and a concentration of 0.87g/cm 3 A density of 3g/10min (I) 2 ) And a maleic anhydride content of 1.0 wt% to 2.0 wt% commercially available from the dow chemical company (The Dow Chemical Company, midland, MI) of Midland, michigan.
ELVALOY TM AC 1820, which is an ethylene/methyl acrylate copolymer, has a melting point of 92℃and a density of 0.942g/cm 3 Melt index (I) 2 ) 8g/10min and an acrylate content of 20 wt% available commercially from the Dow chemical company (The Dow Chemical Company, midland, mich.) of Midland, mich.
INFUSE TM 9507, which is an olefin block copolymer, has a density of 0.866g/cm 3 Melt index (I) 2 ) At 5.0g/10min, commercially available from the Dow chemical company (The Dow Chemical Company, midland, mich.) of Midland, mich.
OmyaFilm 753, calcium carbonate (CaCO) commercially available from Omya AG 3 )。
A film having a final basis weight of 15gsm was formed according to the following formulation and procedure. The formulation of the films was identical to that described in Table 1 below and was designated comparative examples 1-5 and inventive example 1.
TABLE 1 formulation
To form films, the materials of comparative examples 2 to 5 and inventive example 1 were each extruded into a masterbatch formulation on a Buss kneader compounding line. Comparative example 1 did not form a masterbatch formulation because it was a single polymer formulation. The formulation was then processed into a monolayer film on a Collin casting extrusion line. The final film basis weight of the film was 15gsm. The film processing parameters are provided in table 2 below.
TABLE 2 Membrane treatment parameters
| Amps-extrusion C (A) | 2.4 |
| Die head clearance (mm) | 0.8 |
| Layer percentage-extrusion A (%) | 0 |
| Layer percentage-extrusion C (%) | 100 |
| Layer percentage-extrusion E (%) | 0 |
| Melt pressure-extrusion C (bar) | 96 |
| Melt temperature-extrusion C (. Degree. C.) | 231 |
| RPM-extrusion C (RPM) | 29 |
| Structure of the | C |
| Extraction speed (m/min) | 7.7 |
| Total output (kg/h) | 3.8 |
Film sets were produced from each example formulation at different draw ratios. Comparative examples 1A, 2A and inventive example 1A are films having a draw ratio of "0" (i.e., no draw at all). Comparative examples 2B, 3B, 4B and inventive example 1B were stretched in the machine direction to a Minimum Stretch Ratio (MSR) that is inherent to each film. As known to those skilled in the art, the film has an MSR in which the film is fully stretched across its width and is free of tiger stripes. The MSR of comparative example 2B is 3.7:1; the MSR of comparative example 3B is 3.9:1; the MSR of comparative example 4B is 3.7:1; the MSR of example 1B of the present application was 4.2:1. Comparative examples 2C, 3C, 4C and inventive example 1C were stretched in the machine direction to a stretch ratio of 5.5:1.
Machine direction stretching was performed according to machine direction orientation processing parameters in table 3 below.
Table 3: longitudinal directional processing parameters
The WVTR of each example film was measured. The results are provided in table 4 below.
TABLE 4 WVTR results
| Examples | Draw ratio | WVTR(g/(m 2 * Tian)) |
| Comparative example 1A | 0 | 36 |
| Comparative example 2A | 0 | 36 |
| Comparative example 2B | 3.7(MSR) | 3392 |
| Comparative example 2C | 5.5 | 3853 |
| Comparative example 3B | 3.9(MSR) | 3852 |
| Comparative example 3C | 5.5 | 4136 |
| Comparative example 4B | 3.7(MSR) | 3763 |
| Comparative example 4C | 5.5 | 3671 |
| Inventive example 1A | 0 | 35 |
| Inventive example 1B | 4.2(MSR) | 523 |
| Inventive example 1C | 5.5 | 1045 |
Inventive examples 1B and 1C show surprising and unexpected results in which the WVTR values are lower than corresponding comparative examples that were drawn at the same or similar draw ratios and have the same amount of calcium carbonate. Without being bound by any theory, the maleic anhydride functionalized ethylene/α -olefin interpolymer of example 1 of the present application can interact with the filler and the polymer matrix to reduce pore formation, WVTR, and breathability.
The force at 5% strain in MD was also measured. The results are provided in table 5 below.
TABLE 5 force data at 5-5% Strain MD
As shown in table 5, inventive examples 1B and 1C had relatively higher force values at 5% strain in the MD as compared to comparative examples having the same or similar draw ratio and the same amount of calcium carbonate. Thus, the inventive examples show a lower WVTR and improved modulus or force at 5% strain in the MD compared to the corresponding comparative examples. The improved force at 5% strain in the MD can result in an increase in hydrostatic pressure resistance, which is important, for example, during the packaging process and for resisting pressure of liquid that may be trapped in an article such as a diaper when the person sits on the article. The films of the present application exhibit low WVTR values and improved modulus while also incorporating a large amount of low gauge inorganic filler.
Parameter X NBB Can be used to show the advantageous results of the application and inventive example 1. X is X NBB Corresponding to the formula:
calculation of X for comparative examples and inventive examples NBB And are provided in table 6 below.
NBB TABLE 6 results X
| Examples | Draw ratio | X NBB |
| Comparative example 1A | 0 | 0 |
| Comparative example 2A | 0 | 0 |
| Comparative example 2B | 3.7(MSR) | 0.0011 |
| Comparative example 2C | 5.5 | 0.0030 |
| Comparative example 3B | 3.9(MSR) | 0.0010 |
| Comparative example 3C | 5.5 | 0.0019 |
| Comparative example 4B | 3.7(MSR) | 0.0007 |
| Comparative example 4C | 5.5 | 0.0016 |
| Inventive example 1A | 0 | 0 |
| Inventive example 1B | 4.2(MSR) | 0.0108 |
| Inventive example 1C | 5.5 | 0.0113 |
Each document cited herein, including any cross-referenced or related patent or application, and any patent application or patent claiming priority or benefit of the present application, is hereby incorporated by reference in its entirety unless expressly excluded or otherwise limited. Citation of any document is not an admission that it is prior art with respect to any application disclosed or claimed herein, or that it alone or in combination with any one or more other references teaches, suggests or discloses any such application. In addition, in the event that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this document shall govern.
While particular embodiments of the present application have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the application. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this application.
Claims (10)
1. A film, comprising:
(a) 1 to 15 weight percent of an anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer having a melting point of less than 100 ℃;
(b) 20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And
(c) 40 to 70 wt% of an inorganic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; and is also provided with
Wherein weight% is based on the total weight of the film; and is also provided with
Wherein the film has a weight of less than 1,100g/m 2 * A Water Vapor Transmission Rate (WVTR) over days and a draw ratio of at least 2:1.
2. The film of claim 1, wherein the anhydride and/or carboxylic acid functionalized ethylene/a-olefin interpolymer has an anhydride or acid content from 0.1 weight percent to 2.0 weight percent, wherein the weight percent of the anhydride or acid content is based on the total weight of the anhydride and/or carboxylic acid functionalized ethylene/a-olefin interpolymer.
3. The film of any preceding claim, wherein the anhydride and/or carboxylic acid functionalized ethylene/a-olefin interpolymer is a maleic anhydride functionalized ethylene/a-olefin interpolymer.
4. A film according to any preceding claim wherein the inorganic filler is calcium carbonate.
5. The film of any preceding claim, wherein the anhydride and/or carboxylic acid functionalized ethylene/a-olefin interpolymer has a melting point less than 65 ℃.
6. The film of any preceding claim, wherein the film has a basis weight of 5 grams per square meter (gsm) to 50gsm.
7. The film of any preceding claim, wherein the film has a force of greater than 2.000N/15mm film width at 5% strain in the machine direction.
8. The film of any preceding claim, wherein X NBB Is defined as Which is greater than or equal to 0.0060.
9. A laminate comprising the film of any one of the preceding claims in adhering contact with a nonwoven or a second film.
10. A method for manufacturing a film, the method comprising:
providing from 1 to 15 weight percent of an anhydride and/or carboxylic acid functionalized ethylene/α -olefin interpolymer having a melting point of less than 100 ℃;20 to 59 weight percent of a linear low density polyethylene having a weight of 0.900g/cm 3 To 0.940g/cm 3 And a melt index (I) of 0.1g/10min to 10.0g/10min 2 ) The method comprises the steps of carrying out a first treatment on the surface of the And 40 to 70 wt% of an inorganic filler selected from the group consisting of: sodium carbonate, calcium carbonate, magnesium carbonate, barium sulfate, magnesium sulfate, aluminum sulfate, magnesium oxide, calcium oxide, aluminum oxide, mica, talc, silica, clay, glass spheres, titanium dioxide, aluminum hydroxide, zeolite, and combinations thereof; wherein weight% is based on the total weight of the film;
extruding the anhydride and/or carboxylic acid functionalized ethylene/alpha-olefin interpolymer, linear low density polyethylene, and inorganic filler to form the film; and
the film is stretched to a stretch ratio of at least 2:1.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202163153710P | 2021-02-25 | 2021-02-25 | |
| US63/153710 | 2021-02-25 | ||
| PCT/US2022/016972 WO2022182588A1 (en) | 2021-02-25 | 2022-02-18 | Non-breathable films including polymer blends and methods for making the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116867844A true CN116867844A (en) | 2023-10-10 |
Family
ID=80682785
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280015309.0A Pending CN116867844A (en) | 2021-02-25 | 2022-02-18 | Impermeable films comprising polymer blends and methods of making the same |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP4298155A1 (en) |
| JP (1) | JP2024508427A (en) |
| KR (1) | KR20230152063A (en) |
| CN (1) | CN116867844A (en) |
| AR (1) | AR124944A1 (en) |
| WO (1) | WO2022182588A1 (en) |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5843057A (en) * | 1996-07-15 | 1998-12-01 | Kimberly-Clark Worldwide, Inc. | Film-nonwoven laminate containing an adhesively-reinforced stretch-thinned film |
| KR100773737B1 (en) * | 2006-05-10 | 2007-11-09 | (주)대명화학 | Hygienic film with the features of less poly film feeling, less noisy and high opacity |
| ES2419206B1 (en) * | 2012-01-14 | 2014-05-30 | Kloner S.L. | Composition and procedure for obtaining a film of a micro-porous thermoplastic polymer especially suitable for the preparation of personal hygiene items such as diapers and compresses |
-
2022
- 2022-02-18 JP JP2023550060A patent/JP2024508427A/en active Pending
- 2022-02-18 KR KR1020237032005A patent/KR20230152063A/en unknown
- 2022-02-18 CN CN202280015309.0A patent/CN116867844A/en active Pending
- 2022-02-18 WO PCT/US2022/016972 patent/WO2022182588A1/en active Application Filing
- 2022-02-18 EP EP22708681.6A patent/EP4298155A1/en active Pending
- 2022-02-23 AR ARP220100379A patent/AR124944A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| JP2024508427A (en) | 2024-02-27 |
| AR124944A1 (en) | 2023-05-24 |
| EP4298155A1 (en) | 2024-01-03 |
| WO2022182588A1 (en) | 2022-09-01 |
| KR20230152063A (en) | 2023-11-02 |
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